Batch & Lot Traceability

Batch & Lot Traceability is the module Nashua 360 uses to establish complete genealogy across production and distribution. It records the identity, origin and destination of every batch, lot and serial number, from incoming raw material through each transformation to the finished units that leave the dock. The module owns the business problem of provenance and recall: the ability to answer, in minutes rather than days, where any unit came from and everywhere it went.

It sits between quality and logistics in the suite, capturing the material relationships formed at every processing step and holding them as a durable, queryable record. When a defect, contamination or supplier issue surfaces, the module converts that record into a precise, bounded action: exactly which lots are affected, where they now are, and who holds them.

What the module does

The module assigns and governs the identifiers that make material traceable: batch and lot codes for produced and received goods, and serial numbers where individual units must be followed one by one. Every unit of stock carries its provenance, so the system can render a full genealogy tree on demand: parents that were consumed to make it, and children it was later consumed into. From any starting point it performs a backward trace to originating suppliers and receipts, and a forward trace to every customer, shipment and downstream lot that inherited the material.

Around this spine sit the operational controls that make traceability actionable. The module places and releases quality holds and quarantines, records chain of custody at each handover, tracks shelf life and expiry so that first-expired stock moves first, and reconciles quantities across splits, merges, repacks and reworks so that no material is lost or double counted. Recall management draws all of this together, letting an operator scope an affected population, quantify exposure, notify holders and record the disposition of every unit withdrawn.

The domain and data model

At the centre of the domain is the traceable unit: a defined quantity of a specific material that shares a common origin and a common processing history, whether that is a lot of raw ingredient, a manufactured batch, or an individually numbered serial. Each unit knows what it is, how much of it exists, and the quality state it currently holds. The distinguishing idea of the module is that units are never isolated. They are bound to one another through the events in which material is transformed.

A transformation event is the moment where inputs are consumed and outputs are created: a production run, a blend, a repack, a split into smaller units or a merge into a larger one. By recording which units went in and which came out, the module builds a directed lineage that reads in both directions. Following the links upstream reveals ancestry back to supplier receipts; following them downstream reveals descendants all the way to dispatched orders. Layered over this lineage is chain of custody, the sequence of receipts, moves, holds and shipments that records where each unit has been and who was responsible for it. Provenance and location therefore live together, which is what allows a single question to resolve into a single, defensible answer.

Receive & tagTransform &consumeShip & linkTrace & recall
Genealogy forms as material moves, so any unit resolves both backward to origin and forward to destination.

Principal workflows

Traceability begins at receipt. As goods arrive, the module captures the supplier lot, links it to the purchase and quality record, and tags the received stock with its own controlled identifier so that inbound provenance is preserved rather than flattened. On the shop floor, production records the consumption of input lots and the creation of output batches in the same act, so genealogy is formed as work is done rather than reconstructed afterwards. Splits, merges, repacks and reworks are recorded as first-class events, each preserving the material relationships they create.

On the outbound side, dispatch links finished lots and serials to the customer, order and delivery, closing the loop from raw material to recipient. Against this record the core investigative workflows run. A trace query takes any identifier, a supplier lot, a work order, a serial, a customer shipment, and returns the complete forward and backward population. A recall or withdrawal workflow escalates that population into managed action: scoping, holding, notifying, retrieving and dispositioning, with every step and quantity logged for audit and regulator alike.

Functional depth that matters

The module speaks the identification standards that industry supply chains are built on, including global trade item numbers, serialised container and logistics identifiers, and standardised event capture describing what happened to which material, when, where and why. Aggregation and disaggregation are modelled explicitly, so a serial can be followed even as it is cased, palletised and later broken down. This makes the record interoperable with trading partners rather than private to a single plant.

On the control side, the module enforces one-up, one-down visibility as a baseline and extends well beyond it, holding end-to-end lineage that satisfies modern food and pharmaceutical traceability obligations, contamination and allergen containment, and the record-keeping expected under high-risk traceability rules. Mass balance reconciliation compares input and output quantities across every transformation to expose shrinkage, over-issue or unexplained gain. Shelf-life and expiry logic drive first-expired-first-out rotation and quarantine of aged stock. Every hold, release, correction and disposition is captured as an immutable, time-stamped and attributed entry, giving the module the defensible audit trail that certification and regulatory inspection require.

How it fits the Nashua 360 suite

Traceability is deliberately not a silo. It draws inspection results, non-conformances and corrective actions from Quality Management, so a failed test can immediately scope the lots it implicates, and a recall can cite the finding that triggered it. It shares stock, movements and locations with Inventory & Warehouse and Supply Chain, which is how a trace resolves not just to a lot but to the bin, site or vehicle that holds it right now.

Upstream, it binds to Procurement for supplier lots and receipts, and to Manufacturing for the work orders and bills of material that define each production run. Downstream it links to Sales & Order Management for the customers and shipments that received finished goods, and to Document Management for certificates of analysis, specifications and dispatch records attached to each lot. Recall actions surface through Compliance reporting, so obligations to notify authorities and customers are tracked to completion within the same suite that produced the underlying data.

How AI Workers operate inside it

AI Workers are first-class users of the module. An investigator can ask, in plain language, which finished lots contain a suspect supplier batch, or where a given serial was last seen, and the Worker resolves the genealogy and returns the bounded population without a hand-written query. Workers execute actions as well as answer questions: placing holds, opening a recall, scoping affected stock and drafting holder notifications, each subject to the same permissions and audit as a human action.

They run continuously against the record to catch what people miss, flagging mass-balance discrepancies, broken lineage, mislabelled receipts, expiring stock and unusual split or merge patterns as anomalies for review. They extract lot numbers, quantities and dates from inbound certificates and supplier documents and reconcile them against the receipt, so provenance is captured cleanly at the edge. In decision support, a Worker sizes the exposure of a candidate recall, models the trade-off between a broad and a narrow scope, and recommends a disposition. And because Workers participate as named review and approval nodes in workflows, a recall release or a hold override can be routed through an AI Worker that validates completeness and evidence before the action is allowed to proceed.